©2012
Pacific Cycle
27
Models with gear and/or brake cables:
Locate the handlebar assembly. If your model bicycle comes equipped with gears
and/or handbrakes, you will need to be sure that the brake cables and shift cables are
properly routed. Position the handlebar assembly as if you were going to install it, and
take a look at the cables. They should run in a smooth arc from the shifter or brake
lever to the front brake or cable stop on the frame. If they are twisted or kinked, the
shifting and braking will not work. Rotate the handlebars around until the cables are
taking the smoothest route (Fig. 3.5).
There are 2 basic types of handlebar mounting; Quill and Threadless.
Quill Stems
WARNING! Minimum insertion mark must be hidden within the headtube of
the bicycle. Over tightening the stem bolt or headset assembly may cause
damage to the bicycle and/or injury to the rider.
This is a handlebar assembly that has a wedge shaped part at the bottom of the stem
that is inserted into the fork steer tube. Loosen the center bolt enough so that the wedge
and stem can slide into the fork steer tube. Lower the stem until the mark that says
“minimum insertion” is not visible (Fig. 2.5). Tighten the stem center bolt so that the
handlebar assembly is in line with the fork. If needed, you can re-check this after the
front wheel is installed, and re-adjust (Fig. 3.6).
Threadless Stems
This is a handlebar assembly that has a open ended stem with 1 or more pinch bolts that
go outside of the fork steer tube. For this system it is important not to disassemble
the headset and lose any parts. Be sure that the end of the fork is on the ground or
being held with your free hand, because once you loosen the top cap, the fork assembly
may fall out of the frame. Loosen the top cap of the fork steer tube and remove any
cardboard packing, the top cap, and bolt. Set these aside so you can easily retrieve
them. While holding the fork assembly in place, slide the handlebar assembly onto the
fork steer tube. Replace the top cap and bolt. Tighten the top cap bolt only until the
handlebar assembly and fork have no free play, but so that the handlebar assembly and
fork can still freely turn left and right. Then tighten the pinch bolt(s) evenly with the
handlebar assembly facing forward. If needed you can re-check this after the front
wheel in installed, and re-adjust (Fig. 3.7).
Top cap
Pinch
bolt(s)
ASSEMBL
Y
Correct
Incorrect
3.5
3.6
3.7
27
